Well, I'm not sure how your set-up is wired, but there are a few things I can tell you. First, having a manual switch inside the car is only asking for trouble. The fan should have a temp switch (t-stat), and if it doesn't, or if it's faulty, another can be found at any auto parts store. That should be the only way the fan is turned on, or you can also wire it so that it comes on when the A/C is turned on.
If there is a manual switch installed, it needs to control a relay that supplies power to the fan. Most toggle/rocker switches, especially the ones that light up, can't handle the amps that go through that circuit for very long, and will overheat, and start to melt. This will create a short in the system.
Other than that, without seeing a schematic of how yours is wired, I'm afraid there isn't much more I can tell you.
Take care,
~Chris
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